Container and blank therefor



May 25, 1965 v G .A. MOORE 3,135,377

n CONTAIKER AND BLANK THEREFOR I Filed April 4, 1963 2 Sheets-Sheet 1m,zwmzwzmzaum.

' INVENTOR:

ATTORNEY May 25, 1965 e. A. MOORE CONTAINER AND BLANK THEREFOR v 2Sheets-Sheet 2 Filed April 4,1963

INVENTOR ATTORN EY United States Patent 3,185,377 CONTAINER AND BLANKTHEREFOR George Arlington Moore, New York, NY.

. (910 Lake Shore Drive, Chicago, Ill.) Filed Apr. 4, 1963, Ser. No.270,687 14 Claims. (Cl. 229-47) This invention relates to containers forpackaging flowable material, and to a blank from which the container isformed.

More specifically, the invention provides a container havingclosure-forming elements so conceived that it is rendered thoroughlysift-proof, certain of the closureforming elements being uniquelypre-folded and secured integral portions of the fiat container blank.What is more, the container is provided with an eificient dispensingopening arrangement having an independent sub-closure fiap for effectingthe opening and which is also an integral preformed part of the flatcontainer blank prior to shaping the container.

It is well known that present-day containers of the folding cartonvariety are not found to be structurally tight unless they areassociated with interior bags or other lining material and/ oroverwrap-ping sheet materials. These auxiliary materials are neededbecause conventional folded cartons by themselves do not have structuralmeans to make them tight enough to prevent sitting of powdered orgranular material.

It is therefore a primary objectcf the present invention to provide acontainer of the above-mentioned variety that is formed of a novel blankdesigned to render the container leakproof without resorting to the useof any augmenting sheet materials and which can eliminate the use ofconventionally used glue fountain apparatus on carton closing equipment.

Another object of the invention is to provide a novel container-formingblank having pre'folded structural elements formed preliminary to thefolding of the blank as a whole into the body formation of thecontainer, these elements, when further folded, forming the end closuresof the container.

A further object of the invention is to provide a container having adispensing opening facility with manually manipulable sub-closure meansprovided for uncovering and tightly reclosing it.

Another object of the invention is to provide a container-forming blankhaving pre-fol-ded and secured endclosure-forming elements including asub-closure preformed element that is formed to co-act structurally withthe formation of one of the end closures of the container.

It is still a further object to provide a blank adapted for use withthermoplastic film pre-coatings or other adhesive applications that maybe used in forming and sealing the completed container for theparticular duty requirements intended to be fulfilled by the container.

The above and other objects and advantages are attained by thisinvention, a particular embodiment of which I have illustrated in theaccompanying drawings which are utilized for the purpose of illustrationonly, and are not to be construed as a definition of the limits of theinvent-ion, reference being had for this purpose to the 3,185,377Patented May 25, 1965 'FIG. 3a is a cross-sectional view taken on line3a-3a of FIG. 2;

FIG. 4 is a fragmentary perspective view of the set-up container priorto the closing of its end walls;

FIG. 5 is a perspective view showing the completed container as formedfrom the blank in FIG. 2;

FIG. 6 is an enlarged cross-sectional view taken on line 66 of FIG. 5;

FIG. 7 is another enlarged cross-sectional view taken on line 7-7 ofFIG. 5;

FIG. 8 is a view similar to FIG. 6 after the dispenser opening has beenuncovered; and

FIG. 9 is a view similar to FIG. 7 after reclosure of the dispenseropening.

It is contemplated that the container of the present invention will beused to package various types of powdered and granular material forcommercial distribution, the container as formed and closed afterfilling being siftproof. Furthermore, the container may be set up andend closures formed substantially in line with conventional practice andon conventional equipment utilized by the folding carton industry. Useof the present carton will aflord greatly increased efliciency and othereconomical advantages.

To this end, the container forming blank 4 illustrated in FIG. 1 isprepared from any suitable sheet material such as paperboard or otherioldable substrate. For purposes of illustration, any suitable grade ofpaperboard used in making blanks for folding cartons may be utilized andprinted in accordance with conventional practices. The blank 4 as cutand creased from such sheet material consists of the containerbody-forming panels 5, 6, 7 and 8 which will be arranged in opposedpairs. The panel 5 has a longitudinal projected marginal portion 9 usedto form a longitudinal body seam when folding the blank into collapsedand secured condition. Each of the body panels is separated by thelongitudinal score lines 10.

The panel 5 is provided with two outwardly opposed laterally projectingfoldable end closure forming panels 11, the panels 11 each having ascored hinge line 12 perpendicular to the score lines 10. Inoneinstance, for a particular purpose, each of the panels 11 may be coatedon its opposite surfaces with a suitable hot-melt resinous dry adhesivematerial, the purpose of which will be here inafter described. The bodypanel 7 is also provided with two outwardly opposed laterally projectingpanels 13 each having a scored hinge line 14 parallel to the score line12 but spaced outwardly thereof a distance equal to about one thicknessof the blank material.

The body panel 6 is provided with the top and bottom score lines 15 eachdisposed parallel to the score lines 12 and 14 but each spaced inwardlyof the corresponding line 12 a distance equal to subsantially twothicknesses of the blank material. Top and bottom score lines 16 definethe ends of the body panel 8, the lines 16 each being spaced inwardly ofthe corresponding score line 14 a distance equal to substantially threethicknesses of the blank material. The upper part of the panel 6 isprovided with a slit-through section defining an openable aperture area17. At the top of the area 17, the slits 18 converge unwardly. The area17 is coated with a dry activator adhesive indicated by the stripplingthereupon. A U-shaped slit line 19 is provided through the panel spacedbelow the bottom slit line of the area 17.

The panel 6 is also provided with a multiple foldable sub-closureforming panel 20 having two spaced-apart score lines 21 and 22 parallelto score lines 15. The score lines 21 and 22 define the twinledge-forming portions 23 and 24. These twin portions are duplicated onthe bottom end of the panel 6 and upon the top and bottom ends of thebody panel 8 by the ledge-forming portions 34 and 35. The panel portion24 is provided with a pair of spaced-apart perforated lines 25, eachbeing spaced inwardly of the adjacent side edge of the panel andextending between the transverse score lines 22 and 26. The panel 20 isprovided with an outwardly projecting end flange 27 having side edgesextended in line with the perforated lines 25, the flange being providedwith a circular slit tab 28 foldable on the score line 26 of the flange.The base width of the tab is about the same as the width of the U-slitline 19 in the panel 6.

The panel 6 and the first-mentioned twin portions 23 and 24 are providedat their margins with dry activator adhesive in the pattern shown by thestipplcd areas a. The adhesive extends inwardly from the score line 22and terminates substantially in line with the U-shaped slit line 19. Theportions of the pattern adhesive a extending inwardly from the scoreline are adapted to register with the marginal borders 29 of the panel23, the borders 29 being located outwardly of the perforated lines 25and extending between the transverse score lines 22 and 26.

Each of the other twin ledge-forming elments on the bottomend of thebody panel 6 and on the top and bottom ends of the body panel 8 isidentical to the others. Each element is provided with two spaced-apartscore lines 32 and 33 parallel to score lines 15 thereby defining thefoldable margins 34 and 35. The element is also provided with an endflange 36 projecting outwardly from the score line 33. The exteriorsurface of the flange 36 is coated with the adhesive a as are the endsof the twin portions 34 and 35.

The gloss overcoat on the printed blank is not applied to the surface ofthe portion 9, the panels 11 and 20, and the twin elements 23, 24 and34, 35. It is to be understood, that if desired, the entire interiorsurface of the blank may be provided with an extruded or otherwiseapplied plastic film material having thermoplastic properties, such aspolyethylene, polypropylene or any other appropriate material that maybe selected to meet the requirements of the container to be formed fromthe blank. In such event, the panel elements 11 will not be providedwith a coating of adhesive as hereinbefore described, but rather theexterior surfaces thereof will be left uncoated.

The next step taken in finishing the blank 4 is illustrated in FIG. 2wherein the closure forming elements on the ends of the body panels 6and 8 have been folded upon and secured to their respective parentpanels, as shown. The panel and portion 23 are reversely folded alongthe score line 21 into superposed relation with the portion 24 and panel6. As a result, the twin portions assume substantially the form of aslack loop as illustrated in FIG. 3. (FIG. 3 shows the portions 34 and35 but the loop formed by portions 23 and 24 is identical.) The loop isbent inwardly and may be confined at an incline while heat and pressureare applied, by suitable means (not shown), to the panel 20 therebyactivating the dry adhesive a. A bond is thus effected between theopposed marginal portions 29 and central region of the panel 20 and thecorresponding adhesive coated areas of the panel 6. This bond serves tomaintain the portions 23 and 24 in superposed relationship to the panel6. While pressing the panel 20, higher pressure is concentrated upon theperforated lines thereby embossing a groove 37 inwardly upon each ofthese lines as illustrated in FIG. 3a. The purpose served by theembossed grooves will be hereinafter described.

The other end elements 34, 35, 36 are folded in the same manner asdescribed for the panel 20 and elements 23, 24. These elements arefolded along their respective score lines 32, the twin portions 34 and35 being superposed substantially in a slack loop as shown in FIG. 3.The flange 36 of each element is firmly bonded by heat and pressure tothe exterior surface of its respective parent panel as illustrated inFIG. 2. The flange 36 may be bonded in such a position that the loopnormally assumes the inclined condition of FIG. 3 in order to facilitatefurther folding operations. It will now be observed that a sub-closurehas been completely formed in the fiat blank, the sub-closure becomingthe dispenser facility of the completed container. In addition, theother pre-folded and secured elements 34-, 35, 36 as well as theportions 23, 24, constiute ready-made cushion-like resistant seatingledges which the end closure panels of the container will engage inleakproof seam-forming relationship.

The finished blank may be folded and secured in collapsed form byconventional carton folding machines. F or example, the blank 4 may befolded on the score lines 16a and 16b to bring the margin 9 under thepanel 8, whereupon the margin can be adhesively secured to the interiorsurface of the panel 8. The container in collapsed form may be set upalong the lines of conventional practice. Acocrdingly, the container 39is formed from the blank 4 as illustrated in FIG. 4. It will be notedthat the sub-closure dispenser is already completely constructed andsealed as well as the panel seating ledges when the folded blank isopened into carton formation as shown.

The steps taken to form both of the end closures of the container aresubstantially conventional and consist of first folding the slightlyinclined opposing pair of ledges 23, 24 and 34, 35 inwardly anddownwardly so that the upper faces of the elements 23 and 35 of theledges are about parallel to the hinge line 12 of the foldable panel 11.The panel 11 is then folded inwardly and downwardly upon the upper facesof the ledges. Due to the constant tendency of the ledges to springupwardly, they firmly oppose the downward movement of the panel 11.Consequently, the end edge 4%) of the latter is brought intoedge-to-face abutment with the interior surface of the side wall panel 7which simultaneously causes the underlying opposite end edges of theledges to be brought into edge-to-face abutment firmly against theopposing side wall 7 and their opposite end edges against the opposingside wall 5. The panel 13 is then folded inwardly and downwardly uponthe upper face of the folded panel 11. It is important to note that dueto the offset relationships of the hinge lines 12, 14, 15 and 16,provided in the blank, the ledges and panels are positioned uniformly inflat superposed parallel planes. Heat and pressure applied upon the sidewalls 5, 7 adjacent their respective corner edges 12, 1tand upon theexterior surface of the folded panel 13, activates the adhesive upon theinner disposed panel 11 thereby sealing the end closure in leak-proofseam forming relationship. The bottom end closure is formed in the samemanner after filling the container with its intended product.

The completed container is illustrated in FIG. 5, and the end closuresas formed are illustrated in section in FIGS. 6 and 7. It can beobserved that the hot-melt resinous dry adhesive applied upon the panel11, when activated, firmly bonds itself to the upper surfaces of thepressure-resisting ledges and also to the inner face of the panel 13, asshown in the illustrations. In addition, the exudation of the heatedresinous adhesive adjacent the e-dge-to-face abutments, augmented by theadhesive a between the superposed ledges, is the medium that bonds themtogether. These constituted leakproof end closures are permanentthroughout the life of the container inasmuch as the pro-formed novelsub-closure has been provided independently for dispensing purposes.

With further reference to the forming of the fiat top and bottom endclosures of the container, during the application of heat and pressurethereupon, each in a separate stage of operation, the exterior surfacesof the panel 20 and flanges 36 may be contacted by cooling plates toprevent any softening of the adhesive upon these prebonded surfaceswhile sealing the particular end closure. If desired, the adhesive aapplied on these pre-bonded elemen s may be formulated having aheat-softening point sure forming panels 11. These panels constitute asealing gasket medium that renders the end closure construction stronglyreinforced and leakpro-of thus eliminating any need for other augmentingsheet materials, such as insert liners and/or overwraps, and the use ofany adhesive applying apparatus.

The present invention in instances contemplates the use of plastic filmmaterial upon the interior surfaces of the container for protectivepurposes in keeping with its particular duty to be performed by thecontainer. In such instance, the interior face of the blank shown inFIG. 1 may be coated, extruded or laminated with a selected plastic filmmaterial, such as polyethylene, poly propylene, Pliofilin, vinyl orother desired'material, preferably having thermoplastic properties. Insuch event, the

panels 11 need not be separately coated with resinous adhesive. Also,referring to FIG. 2, the plastic film will be on the exterior face ofthe pre-folded and secured elements. Therefore, wheneffecting the bondsof these elements as herei-nbefore described, the heating andpressure-applying apparatus rnernbersare provided with tack insulatedsurfaces to avoid sticking to the panel surface and flanges 36.Accordingly when for-ming'the container the plastic film is utilized asthe medium for bonding the end closures thereof.

The completed container as shown in FIG. 5 is strongly reinforced yetmay be easily and cleanly opened by the consumer in the mannerillustrated in FIGS. 6 and 8. The flange 27 is grasped and pulledoutwardly causing the central wall portion of the panel 2% to severitself progressively along the perforated lines thus pulling the bondedwall portion 17 out of the side wall 6 leaving an aperture 17a throughwhich to dispense the product from the container. Due to the embossedgrooves 37 along the perforated lines 25, the density of the blankmaterial along these lines is greatly increased, causing the material tocleanly separate in an orderly manner that avoids mutilation or unduefraying of the material. Furthermore, the embossed grooves serve tostiffen the panel. The severed panel portion pivots freely on the scorehinge line 22. The bonded marginal sides 29 of the panel 20 remainintact. After tilting the opened container for dispensing the desiredamount of product therefrom, the severed panel portion may be restoredto substantially its original position and tightly retained therein.This is accomplished by pressing on the tab 28 in the flange 27 in orderto bend it inwardly, as. shown in dotted lines in FIG. 8, and theninserting it into the U-shaped slit 19. The plug 17 on the panelreenters the aperture 17a, and the insert tab 28 is gripped by theyielded wall part do defined by the slit line 1d thereby tightlylatching the reclosure as illustrated in FIG. 9. The dispenser closuremay beopened and reclosed many times without loss of its efficiency inbeing released and tightly restored. The unique manner provided forpivoting the severed section of the panel 20 insures the registry of theplug 17 in the aperture 17a. The novel latch and plug means describedand illustrated insures stability of the dispenser reclosure againstbeing jarred loose.

It is contemplated that the flat blank of the present invention may beprovided on both its faces with a film of thermoplastic material, suchas polyethylene. In such a case, the dry activator adhesive a describedabove need not be provided on the exterior surface of the blank sincethe thermoplastic film will serve in its place. Instead, a pattern ofnon-thermoplastic material, such as a heat-resistant lacquer, is appliedto the area of the outer surface of the panel 6 which eventuallyunderlies the central portion of the panel 20 between the perforatedlines 25. However, the non-thermoplastic material is not applied to thesection 17. As a result, when the flange 27 is grasped and pulled, thecentral portion of the panel 20 will freely separate from the panel 6 asit is severed along the perforated lines 25, and will pull the section17 with it.

In addition, the flanges 36 may be eliminated and the por tions 34- and35 bonded together in prefolded condition by the thermoplastic coatingon their exterior faces.

The invention has been shown and described in preferred form only, andby way of example, and many variations may be made in the inventionwhich will still be comprised within its spirit. It is understood,therefore, that the invention is not limited to any specific form orembodiment except insofar as such limitations are included in theappended claims.

What is claimed is:

1. A carton blank of foldable material comprising hinged panels adaptedto form the front, rear, and side walls of said carton, when said cartonis in folded condition one of said side wall panels being slit to definea removable section adjacent to its end edge, said section when removedforming a dispensing aperture, panels hinged to the end edges of thefront and rear wall panels and adapted to overlie each other to form anend wall of said carton, ledge-forming panels secured by connectinghinges to the end edges of the side wall panels respectively and adaptedto form ledges underlying the end wall of the carton, each ledge-formingpanel comprising adjacent twin portions hinged together along a lineparallel to the connecting hinge, a cover panel for said removablesection hingedly connected to and integral with the outer edge of theouter twin portion of the ledgeforming panel nearest said removablesection, a flange hingedly connected to the outer edge of the outer twinportion of each of the remaining ledge-forming panels, saidledge-forming panels being adapted to be turned back upon themselves toform two-ply slack loop cushionlike resistant seating ledges and tobring said cover panel and flanges into overlying relationship upon theouter surfaces of their respective side wall panels, and adhesive meansadapted to secure said cover panel and flanges to said side wall panels.

2. A carton blank as defined in claim 1 wherein said cover panel has acentral region larger than said removable section, marginal areasflanking said central region, and a line of perforations between eachmarginal area and said central region, said adhesive means being adaptedto secure said marginal areas to said side wall panel but said centralregion being adapted to remain free of permanent attachment to said sidewall panel whereby said central region may be swung away from said sidewall by severing it from said marginal areas along said lines ofperforations.

3. A carton blank as defined in claim 2 wherein said adhesive means isadapted to secure said removable section to the inner surface of saidcentral region whereby when said central region is swung away from saidside wall panel it carries said removable section with it therebyforming a dispensing aperture in said side wall panel.

4. A carton blank as defined in claim 2 wherein said cover panel isprovided with embossed grooves Within which said perforated lines arelocated.

5. A carton blank having inner and outer surfaces and comprising hingedpanels adapted to form the front, rear, and side walls of said cartonwhen said carton is in folded condition, panels hinged to the end edgesof said front and rear wall panels and adapted to overlie each other toform an end wall of said carton, two-ply ledgeforming elements adaptedto form slack loop cushionlike resistant seating ledges projectingperpendicularly from said side wall panels and underlying said end wallof said carton, the inner ply of each of said elements secured by aconnecting hinge to the end edge of its respective side wall panel, aflange hingedly connected to the outer edge of the outer ply of each ofsaid elements, said flange being adhesively secured to the outer surfaceof its respective side wall panel in such a location that said elementis bent inwardly at an acute angle to the side wall panel normallyassuming an inclined condition and maintained in that condition wherebysaid ledges will resist being moved to a perpendicular positionunderlying said end wall of said carton and will tend to exert anoutward force on the inner face of said end wall.

6. Acarton blank as defined in claim 5 wherein said plies of each ofsaid ledge-forming elements are integral and joined along their inneredges by a hinge.

7. A carton blank as defined in claim 5 wherein one of said side wallpanels is slit to define a removable section adjacent to its end edge,said section when removed forming a dispensing aperture, and the. flangesecured to and integral with said one side wall panel is relativelylarge and forms a cover panel for said removable section.

8. A carton formed from the blank defined in claim 1.

9. A carton formed from the blank defined in claim 5.

10. A fiat container forming blank of sheet material cut and creased todefine side wall panels and integral end closing foldable elements, oneof said side wall panels being provided with a slit removable sectionand an integral projected foldable panel sectionally divided by creasedlines, one of which defines its ultimate hinge, the exterior surface ofsaid projected panel having an applied pattern of dry adhesive thereuponand a pair of surface embossed and aligned perforated cut lines thereinto sectionally divide said panel transversely and outwardly in its hingeline, said panel being folded inwardly and downwardly 180 degrees from acreased line spaced inwardly of and parallel with said hinge line,whereby two substantially equal marginal wall portions at the base ofsaid panel are superposed and extended outwardly of the end of the oneside wall, and the section of the folded panel defined by the cut linesbeing flatly disposed thereupon, heat and pressure being applied theretoto activate said adhesive to secure said panel upon the side wall andupon its removable section adapted to provide an openable dispensingsub-closure construction in said blank prior to forming the containerthereof.

11. A fiat blank according to claim 10 wherein said folded superposedmargins provide a two-ply slack loop cushion-like resistant panelseating ledge for another of said end closing elements when foldedthereupon in forming the end closure of the container adjacent thepreformed dispensing sub-closure construction.

12. In a container forming blank of suitable sheet material whichincludes a pre-folded sub-closure forming element that covers adispensing aperture provided in a side wall forming panel of said blank,said pre-folded element having a projected superposed marginal ledgeportion folded and secured to provide a two-ply slack loop cushion-likeresistant seating ledge to be coactive in structure when forming the endclosure of said container adjacent said pre-folded sub-closure.

13. A folding carton blank of sheet material cut and creased to definefour side wall forming panels each having foldable end closure formingelements, one of said side wall panels being provided with a slitremovable and replaceable section to define a dispensing aperture whensaid carton is in folded condition, a panel element hinged to andintegral with an end of said side wall panel adjacent said slit section,the latter panel having two foldable marginal portions of substantiallyequal areas and a further projected foldable wall portion having a hingethat defines the outer end of said two marginal portions thereof, saidhinged panel having sectionally defined border embossed lines cutcentrally thereof for severance and a pattern applied dry adhesiveadapted when activated to secure said panel upon the surface of said oneside wall panel including its removable section, said two marginalportions being superposed when folded and adapted to form a two-plyslack loop cushion-like resistant seating ledge for one of the otherclosure forming elements when being folded to close an end of saidcarton.

14. A folding carton blank according to claim 13 Wherein said borderembossed lines provide means for effecting clean lines for partialseparation of said hinged panel and for stiffening the side edgesthereof when being severed along said cut lines in the borders therebyarresting the tendency of the released sectional part of said panel towarp out of its original flat shape.

References Cited by the Examiner UNITED STATES PATENTS 1,482,857 2/24Moore 22945 1,956,238 4/34 Jackson 22917 2,218,670 19/40 Bennett 229-443,070,277 12/62 Moore 22937 3,104,793 9/63 Hickin 229-17 FRANKLIN T.GARRETT, Primary Examiner.

1. A CARTON BLANK OF FOLDABLE MATERIAL COMPRISING HINGED PANELS ADAPTEDTO FORM THE FRONT, REAR, AND SIDE WALLS OF SAID CARTON, WHEN SAID CARTONIS IN FOLDED CONDITION ONE OF SAID SIDE WALL PANELS BEING SLIT TO DEFINEA REMOVABLE SECTION ADJACENT TO ITS END EDGE, SAID SECTION WHEN REMOVEDFORMING A DISPENSING APERTURE, PANELS HINGED TO THE END EDGES OF THEFRONT AND REAR WALL PANELS AND ADAPTED TO OVERLIE EACH OTHER TO FORM ANEND WALL OF SAID CARTON, LEDGE-FORMING PANELS SECURED BY CONNECTINGHINGES TO THE END EDGES OF THE SIDE WALL PANELS RESPECTIVELY AND ADAPTEDTO FORM LEDGES UNDERLYING THE END WALL OF THE CARTON, EACH LEDGE-FORMINGPANEL COMPRISING ADJACENT TWIN PORTIONS HINGED TOGETHER ALONG A LINEPARALLEL TO THE CONNECTING HINGE, A COVER PANEL FOR SAID REMOVABLESECTION HINGEDLY CONNECTED TO AND INTEGRAL WITH THE OUTER EDGE OF THEOUTER TWIN PORTION OF THE EDGEFORMING PANEL NEAREST SAID REMOVABLESECTION, A FLANGE HINGEDLY CONNECTED TO THE OUTER EDGE OF THE OUTERTWINLS, PORTION OF EACH OF THE REMAINING LEDGE-FORMING PANELS, SAIDLEDGE-FORMING PANELS BEING ADAPTED TO BE TURNED BACK UPON THEMSELVES TOFORM TWO-PLY SLACK LOOP CUSHIONLIKE RESISTANT SEATING LEDGES AND TOBRING SAID COVER PANEL AND FLANGES INTO OVERLYING RELATIONSHIP UPON THEOUTER SURFACES OF THEIR RESPECTIVE SIDE WALL PANELS, AND ADHESIVE MEANSADAPTED TO SECURE SAID COVER PANEL AND FLANGES TO SAID SIDE WALL PANELS.